Need help! PS3 HDD upgrade corrupted data!

OMG! This has been the most frustarting thing I have ever been through install wise.

I took my PS3 HDD out to run diagnostics on it. While I had it connected to my PC, I decided to give it a fresh format as well. I fully formatted it with all zero's, and tryed to install back...data corrupted it told me for the update it prompted me for. I downloaded another 3.56 firmware, same thing. I tried formatting it to NTSC...same thing corrupted data. FAT32...corrupted data.

I've tryed differant usb drive...corrupted data!

GUYS WHAT IS GOING ON HERE!?

Am I completly missing something, or is my PS3 fried for some reason? I have upgraded hdd's before on 2 differant PS3s. NEVER this much of a problem.